Snap switch with pre-wired terminals

ABSTRACT

Spade type terminals are crimped on to the ends of lead wires. After such crimping the terminals are inserted into the housing of a switch and lock in place. The switch is provided with a toggle actuator to effect movement of a movable switch contact with a snap action between the inserted terminals serving as fixed contacts.

United States Patent [191 Bury SNAP SWITCH WITH PRE-WIRED TERMINALSInventor: Allen J. Bury, Prospect Heights, 111.

Molex, Incorporated, Downers Grove, 111.

Filed: Jan. 3, 1972 Appl. No.2 215,022

Assignee:

US. Cl. 200/67 C, 200/ 166 CT Int. Cl. H0lh 13/26 Field of Search 200/67G, 166 CT,

[56] References Cited UNITED STATES PATENTS Guett 200/67 A Horecky Longet a1. 200/166 CT Jan. 15, 1974 1,642,743 9/1927 Newton 200/67 C2,633,510 3/1953 Sche11man.. ZOO/153 .1 3,175,067 3/1965 Barcus 200/166CT 2,151,612 3/1939 Morris 200/67 C FOREIGN PATENTS OR APPLICATIONS1,088,616 10/1967 Great Britain 200/68 Primary Examiner-David Smith,vJr. Attorney-Roy H. Olson et al.

ABSTRACT Spade type terminals are crimped on to the ends of lead wires.After such crimping the terminals are inserted into the housing of aswitch and lock in place. The switch is provided with a toggle actuatorto effect movement of a movable switch contact with a snap actionbetween the inserted terminals serving as fixed contacts. 1

7 Claims, 17 Drawing Figures Q 55 S 4032 34 s 1 SNAP SWITCH WITHPRE-WIRED TERMINALS BACKGROUND OF INVENTION Crimp connection ofterminals to lead wires is well known. In a case of minature switchesthe space available for terminals often makes crimping in place verydifficult. Accordingly, it has been proposed heretofore to crimpterminals on to lead wires, and thereafter to insert the terminals intothe housing of a switch to latch in place and serve as the fixedcontacts for the switch, see for example Stanley V. Horecky US. Pat. No.3,501,599 and Bruno Baumanis US. Pat. No. 3,488,460.

For many types of installations a certain degree of inpositive action inswitching can be tolerated. However, in other installations teasing ofthe contacts cannot be tolerated.

OBJECTS AND SUMMARY OF THE INVENTION Accordingly, it is an object of thepresent invention to provide a snap action switch in which terminals arecrimped on to the lead wires and are thereafter inserted into the switchhousing for engagement by a movable contact.

More particularly, it is an objectof the present invention to providesuch a switch utilizing spade type terminals and further employing atoggle mechanism for effecting snapping of the movable contact from oneposition to another.

In accordance with the present invention the switch is provided with atoggle mechanism. This may be operated by a slide member, a rocker, orby a push button. The movable contact is provided with shorting barsections at either ends. Three sets of spade type terminals are crimpedon to the ends of lead wires, and thereafter are inserted into slotsprovided therefor in the housing. The terminals are provided withresilient lances for latching them in place upon insertion. Theterminals are positioned for engagement in pairs by the shorting barcontacts of the movable switch contact, and serve as fixed contacts forthe switch.

SUMMARY OF THE DRAWINGS AND DETAILED DISCLOSURE The invention will bestbe understood with reference to the following description when taken inconnection with the appended drawings wherein:

FIG. 1 is a side view of a switch constructed in accordance with theprinciples of the present invention, the manual operating member being aslide;

FIG. 2 is an end view of the switch of FIG. 1;

FIG. 3 is a longitudinal sectional view therethrough as takensubstantially along the line 33in FIG. 2;

FIG. 4 is a fragmentary front view showingthe terminals crimped on tothe lead wires prior toinsertionin the switch housing;

FIG. 5 is a top view of the terminals of FIG. 4;

FIG. 6is a longitudinal view similar to FIG. 3 showing the parts in adifferent position of operation;

FIG. 7 is a cross-sectional view taken substantially along the line 7-7of FIG. 1;

FIG. 8 is a horizontal upwardly looking section as taken substantiallyalong the line 88 in FIG. 1;

FIG. 9 is a detail view of the movable switch member;

FIG. 10 is across-sectional view through the movable switch member astaken along the line 10-10 of FIG.

FIG. 11 is a fragmentary longitudinal sectional view on an enlargedscale as taken substantially along the line 11-11 in FIG. 9;

FIG. 12 is a fragmentary longitudinal sectional view similar to the topportion of FIG. 3 showing a modification of the invention utilizing arocker member as the manually operable switch actuator;

FIG. 13 is a fragmentary end view of the embodiment of FIG. 12;

FIG. 14 is a fragmentary side view of a further embodiment of theinvention utilizing a push button as a manually operable actuator;

FIG. 15 is an end view of the embodiment of FIG. 14;

FIG. 16 is a fragmentary longitudinal sectional view as takensubstantially alongthe line 16-16 in FIG. 15; and

FIG. 17 is a fragmentary cross-sectional view as taken substantiallyalong the line 1.7 in FIG. 14.

Turning now in greater particularity to the drawings, and first to FIGS.l-8, there will be seen a snap action switch 20 constructed inaccordance with the principles of the present invention. The switchcomprises a molded plastic housing 22 having a generally rectangularcentral body 24. Integral end portions 26 extend in opposite directionsfrom the central body and are of lesser height than the central body.

Projections 28 on the front and back faces of the central body serve tomount a generally channel-shaped metal mounting structure 30 having anupper web 32 with apertures 34 therein for receipt of fasteners such asscrew fasteners for mounting the switch.

The central body 24 has an upstanding integral superstructure 36 with alongitudinal passage 38 therein having a dovetail undercut 40 providinga slideway. Lateral flanges 42 of a manually operable slide 44 arereceived in the slideway 40 to guide the manually operable member 44 inlongitudinal sliding movement. The member 44 has an upstanding centralportion 46 with a ribbed or knurled top surface 48 for engagement by athumb or other finger of an operator. The member 44 also is providedwith hollow, downwardly opening de' pending central section 50.

A generally upright rocker member 52 of sheet metal construction ispivoted on a transverse pin 54 and extends through an opening 56 in thetop of the central body 24. The operator 52 is provided at its upper endwith a ball 58 received in the depending hollow portion 50 of themanually operable member 44 as is best seen in FIGS. 3 and 6. Outwardlyof the ball 58, the rocker 52 is provided with diverging upstanding arms60 having inclined outer surfaces 62 alternately engageable with obliquestop surfaces 64. The central body 24 is provided with a pair of opposedinternal recesses 66 receiving pivot members 68 of a rocker 70. As bestmay be seen in FIGS. 3, 9 and 10, the rocker 70 comprises an elongatedchannel-shaped section of plastic material having a triangular upperextension 72 with an aperture 74 in a boss 76 at the upper extremitythereof. The pivot members 68 are provided with relatively smalldiameter central shanks 78 which snap into recesses 80 in the sidewallsof the channel-shaped rocker. Pairs of channel-shaped contact members 78preferably are secured to the opposite ends of the rocker 70 by means oflances (not shown) or by any other suitable means,

such as an adhesive, or such as by projections integral with the rockermember extending through apertures in the contact members 78 and heatsoftened and pressed into enlargements whereby to hold the contacts inplace. As best may be seen in FIG. 11, each contact 78 ischannel-shaped, comprising a narrow web 80 and parallel flanges 82diverging at the outer ends at 84. A slot 86 (FIG. 9) in each flangeprovides for independent resilience of the opposite ends of thechannels, the contact 78 being formed of suitable contact metal.

One end 86 of a coiled over-centering spring 88 extends through the hole74 in the top of the flange extension 72, the other end 90 thereofextending through a hole 92 in the lower end of the rocker 52.

As the manually engageable operator 44 is longitudinally shifted backand forth, it rocks the rocker 52 and causes the spring 88 toover-center, whereby to snap the rocker 70 back and forth between thepositions of FIGS. 3 and 6.

Turning attention now to FIGS. 4 and 5, lead wires are shown at 94, andin the illustrative example there are six such wires at each end of thehousing, being in horizontally spaced pairs of three, thethree of eachpair being disposed above one another in a common plane for installationin the housing. Each feed wire comprises a conductor 96, which may bestranded or solid, and conventionally of copper. The conductor 96 ineach instance is covered with insulation 98, which conventionally is ofa thermal plastic nature.

Each lead wire 94 has a terminal 100 crimped on the end thereof. Eachterminal comprises spade-like body 102 with an integral offset 104connecting it to a ferrule or barrel 106 having arms 108 for crimping onto the conductor 96, and arms 1 for crimping on to the installation,such crimp connections being known in the art. A resilient lance or tang112 is struck from the body and has a free end 114 spaced from andconfronting the offset 104.

Each end portion 26 is provided substantially midway from top to bottomwith an enlargement or protuberance 116. Cavities 118 are provided inend portions 26 and in the protuberances 1 16, there being a total ofsix such cavities in either end of the housing in horizontally spacedsets of three each. Due to the protuberances 116 the central of thesecavities 118 are spaced outwardly further from the housing body 24. Eachcavity as seen particularly in FIG. 8, is provided with a narrowaperture 120 at its inner end thereby forming a substantially rightangle shoulder 122 engageable by the terminal offset 104 to limit thedepth of insertion of each terminal. Forwardly of each shoulder 122there is an oppositely disposed internal right angle shoulder 124engaged by the corresponding rearwardly struck lance or tang 112 toprevent retraction of the terminal. With the terminals inserted asaforesaid, the bodies 102 thereof extend into the position shown inFIGS. 3, 6 and 8 so that diagonally opposed pairs thereof may be spannedby the movable contact 78 on the rocker 70. As will be apparent, thechannel-shaped contacts 78 grip resiliently on opposite sides of theterminal bodies 102, forming therewith respective movable and fixedcontacts which engage with a wiping motion so as to rub off surfacecorrosion, dirt, etc. The limit position of the rocker 70 in either FIG.3 or FIG. 6 is determined by engagement of the web 80 of the contactwith the end of the central terminal body 102.

Although not specifically discussed heretofore, the housing is formed astwo mirror-image portions butted together along a vertical line 126, andsecured by means of the mounting clip or structure 30. Similarly, forsimplicity of molding, the superstructure 36 may be molded as a separatepiece and suitably secured to the remainder of the housing, althoughthis is not essential.

A modification of the invention is shown in FIGS. 12 and 13. Most of theparts are identical with those heretofore shown and described, and henceare not again described, being identified by the same numerals forpurposes of identification. The distinquishing feature is that themanually engageable operator 44 is a rocker member, pivotally mounted byintegral bosses 128 in the superstructure 36, having a hollow dependingportion 48 receiving the ball 58, and at its upper edge having twomanually engageable surfaces 130 at an obtuse angle to one another forrocking back and forth under the thumb.

A further embodiment of the invention is shown in FIGS. 14-17. Most ofthe parts again are exactly the same, being shown only in part, andbeing identified by the same numerals as used heretofore. Thedistinquishing feature of the invention of FIGS. 14 and 16 is that avertically operable push button 44b comprises the manually engageableoperator. The push button is vertically slideable up and down on thesuperstructure 36, having teeth 132 on the lower ends thereof lockingbeneath shoulders 144 to limit upward movement of the push button.Springs 136 resiliently urge the push button up to its limit of verticalmovement. The push button 44b is hollow, and is provided centrallythereof with a flexible tongue I38 tapered nearly to a point at thelower end as indicated in 140. The rocker 52 has a tri angular shapedprojection 142 at the top end thereof rather than the ball 58,otherwise, being shaped the same as heretofore described. When the pushbutton moves down to position as shown in FIG. 16, it will engage thenotch 144 to the left of the triangular projection 142, and the tonque138 will flex to the left as the operator is rocked in acounterclockwise direction. On a succeeding (or preceding) depression ofthe push button the tongue 138 will fall into the notch 144 to the rightof the upper projection 142, and will rock the operator in a clockwisedirection with the tongue flexing to the right as shown in broken linesin FIG. 16.

In each example of the present invention terminals are applied to wires(sometimes referred to as preterminated wires), the terminals then beinginserted into complementary openings in the ends of a switch housing.The terminals then form fixed contacts engageable with a snap-actionfloating contact for completing electric circuits.

These specific examples of this invention as herein shown and describedare for illustrative purposes only. Various changes in structure will nodoubt occur to those skilled in the art, and will be understood asforming a part of the present invention insofar as they fall within thespirit and scope of the appended claims.

The invention is claimed as follows:

1. An electric snap switch comprising a housing having a cavity therein,a rocker pivotally mounted in said cavity, a switch operator pivotallymounted from said housing and disposed at least in part in said cavity,a coiled overcentering spring having one free end connected to saidoperator and the other free end connected to said rocker, such that uponpivotal movement of said operator, said rocker will be moved back andforth between two rest positions with a snap action, at least two seriesof apertures extending through said housing and communicating with saidcavity, each said series including at least three apertures withrespective apertures of each series being in alignment with the apeturesof the other series and diametrically opposed substantially in a commonplane, and at least two series of substantially flat blade-typeterminals preassembled with lead wires and inserted in said apertureswith at least portions thereof extending into said cavity substantiallyin said common plane, said terminals and said housing havingcomplementary structures latching said terminals in said housing, saidrocker having a pair of electric contact means thereon substantially insaid common plane and each said contact means having sufficient widthsuch that in one or the other of said rest portions each contact willengage the center terminal of the series of terminals associatedtherewith and one or the other of the two aligned terminals of saidseries.

2. A snap switch as set forth in claim 1 and further including amanually engageable member movably mounted on said housing andinterconnected with said operator for moving said operator in responseto manual movement of said member.

3. A snap switch as set forth in claim 2 wherein the manually engageablemember comprises a slide memher.

4. A snap switch as set forth in claim 2 wherein the manually engageablemember comprises a rocker.

5. A snap switch as set forth in claim 2 wherein the manually engageablemember comprises a push button.

6. A snap switch as set forth in claim 1 wherein the rocker electriccontact is channel-shaped and has a pair of flanges embracing saidterminals.

7. A snap switchas set forth in claim 6 wherein outer portions of saidflanges are turned out to facilitate embracing said terminals.

1. An electric snap switch comprising a housing having a cavity therein,a rocker pivotally mounted in said cavity, a switch operator pivotallymounted from said housing and disposed at least in part in said cavity,a coiled overcentering spring having one free end connected to saidoperator and the other free end connected to said rocker, such that uponpivotal movement of said operator, said rocker will be moved back andforth between two rest positions with a snap action, at least two seriesof apertures extending through said housing and communicating with saidcavity, each said series including at least three apertures withrespective apertures of each series being in alignment with theapertures of the other series and diametrically opposed substantially ina common plane, and at least two series of substantially flat blade-typeterminals preassembled with lead wires and inserted in said apertureswith at least portions thereof extending into said cavity substantiallyin said common plane, said terminals and said housing havingcomplementary structures latching said terminals in said housing, saidrocker having a pair of electric contact means thereon substantially insaid common plane and each said contact means having sufficient widthsuch that in one or the other of said rest portions each contact willengage the center terminal of the series of terminals associatedtherewith and one or the other of the two aligned terminals of saidseries.
 2. A snap switch as set forth in claim 1 and further including amanually engageable member movably mounted on said housing andinterconnected with said operator for moving said operator in responseto manual movement of said member.
 3. A snap switch as set forth inclaim 2 wherein the manually engageable member comprises a slide member.4. A snap switch as set forth in claim 2 wherein the manually engageablemember comprises a rocker.
 5. A snap switch as set forth in claim 2wherein the manually engageable member comprises A push button.
 6. Asnap switch as set forth in claim 1 wherein the rocker electric contactis channel-shaped and has a pair of flanges embracing said terminals. 7.A snap switch as set forth in claim 6 wherein outer portions of saidflanges are turned out to facilitate embracing said terminals.